US9651252B2 - System for CO2 capture from a combustion flue gas using a CaO/CaCO3 chemical loop - Google Patents

System for CO2 capture from a combustion flue gas using a CaO/CaCO3 chemical loop Download PDF

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US9651252B2
US9651252B2 US14/291,167 US201414291167A US9651252B2 US 9651252 B2 US9651252 B2 US 9651252B2 US 201414291167 A US201414291167 A US 201414291167A US 9651252 B2 US9651252 B2 US 9651252B2
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cyclone
flue gas
calciner
solids
pipe
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US20140352581A1 (en
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Juan Carlos Abanades Garcia
Borja ARIAS ROZADA
Maria Elena Diego de Paz
Isabel Martinez Berges
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Consejo Superior de Investigaciones Cientificas CSIC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/46—Removing components of defined structure
    • B01D53/62—Carbon oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/02—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/81—Solid phase processes
    • B01D53/83—Solid phase processes with moving reactants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/96—Regeneration, reactivation or recycling of reactants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2251/00—Reactants
    • B01D2251/40—Alkaline earth metal or magnesium compounds
    • B01D2251/404—Alkaline earth metal or magnesium compounds of calcium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/50—Carbon oxides
    • B01D2257/504—Carbon dioxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/02—Other waste gases
    • B01D2258/0283—Flue gases
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
    • Y02C10/04—
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02C—CAPTURE, STORAGE, SEQUESTRATION OR DISPOSAL OF GREENHOUSE GASES [GHG]
    • Y02C20/00—Capture or disposal of greenhouse gases
    • Y02C20/40—Capture or disposal of greenhouse gases of CO2
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/32—Direct CO2 mitigation
    • Y02E20/326—
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/10—Biofuels, e.g. bio-diesel
    • Y02E50/12—

Definitions

  • This invention relates to a system for CO 2 capture from a combustion flue gas using a CaO/CaCO 3 chemical loop, wherein the CO 2 is captured from large scale combustion systems using CaO as regenerable CO 2 sorbent, where CaO particles are carbonated in contact with a flue gas at around 650° C. to later release pure CO 2 when supplied with sufficient heat for CaCO 3 calcination at around 900° C.
  • the system of this invention is characterized by a first direct heat exchange from a high temperature flue gas to a recirculation stream of calcined solids from the calciner and a second direct heat exchange from a flue gas to the carbonated solids arriving to the calciner, thereby reducing the heat requirements for calcination.
  • Part of the flue gas used in the second heat exchange operation is the flue gas resulting from the first direct heat exchange operation.
  • the flue gas resulting from the second heat exchange operation is fed to the carbonator reactor for CO 2 capture and for the formation of the carbonated solids.
  • Ca-looping CO 2 capture system One particular type of advanced CO 2 capture technology makes use of a CaO/CaCO 3 reversible reaction or chemical loop, and is known as the Ca-looping CO 2 capture system or carbonate looping.
  • the flue gas from a power plant or other industrial emitter is first put in contact with CaO to absorb CO 2 and form CaCO 3 in a carbonator reactor that emits a flue gas with a reduced content of CO 2 .
  • the stream of carbonates solids containing CaCO 3 is calcined in a circulating fluidized bed calciner reactor burning a fuel with a mixture of O 2 /CO 2 at a temperature around or above 900° C. in an atmosphere of concentrated CO 2 .
  • the circulating fluidized bed carbonator reactor and circulating fluidized bed calciner reactor have been interconnected in order to establish a solid flow of carbonated solids from the carbonator to the calciner, an equivalent solid flow of calcined solids from the calciner to the carbonator, a recirculation flow of carbonated solids leaving the carbonator and entering the carbonator and a recirculation flow of calcined solids leaving the calciner and entering the calciner.
  • the two recirculation solid streams have been set up in order to increase the residence time and inventories of solids in the risers of the carbonator and calciner reactors, as it is common practice in the state of the art of other circulating fluidized bed systems.
  • the split of the solids leaving each of the reactors into an stream of recirculating solids and a stream of solids circulating to the other reactor can be achieved with state of the art devices (double loop seals or other devices to split solid flows in standpipes) or can be arranged to be associated to different cyclones connected to the risers (one or more cyclones would direct the recirculating solids back to the same reactor while other or others cyclones would direct the solids to the other reactor).
  • postcombustion Calcium looping can also be applied to flue gases coming from natural gas combined cycles (Berstad, D., Anantharaman, R., Jordal, K. Int. Journal of Greenhouse Gas Control 2012, 11, 25) as the low partial pressures of CO 2 typical in these flue gases can be increased with a flue gas recycle, as applied to other postcombustion CO 2 capture process routes.
  • Sceats and Dindsdale disclose a novel Ca-looping, in which heat from a high pressure carbonation stage (at temperature slightly over the calciner temperature) is transferred (again indirectly through a wall) to the calciner to partially drive the calcination reaction of CaCO 3 . They use a modest temperature difference between the carbonator and calciner. Therefore, important practical problems can be anticipated for this heat transfer stage as the required heat transfer surface must be very large to allow required heat transfer for the highly endothermic calcination of CaCO 3 .
  • This invention refers to a system to capture CO 2 from a combustion flue gas using a CaO/CaCO 3 chemical loop comprising at least the following elements:
  • This high temperature flue gas can be generated by adiabatic combustion of a fuel with air in a separated second combustor or it can be part or all of the flue gas generated in the first combustor, as long as this flue gas is at suitably high temperature for the purpose of the invention.
  • different fuel and different combustion conditions can be used in each combustor.
  • the system of this invention is also intended to take heat directly from the high temperature flue gases generated in the combustion chamber and direct this heat towards the calciner using the circulating stream of carbonated solids from the carbonator entering the calciner.
  • the objective of such heat transfer exercise is to heat up in the fourth cyclone the solid circulation stream of carbonated solids to a temperature as close as possible to the maximum decomposition temperature of CaCO 3 under the gas-solid contact conditions in such cyclone.
  • a conservative assumption for the temperature of the overheated stream of carbonated solids would be the equilibrium decomposition temperature of CaCO 3 (750° C.-780° C.) under the CO 2 partial pressures in the flue gases that abandons the combustion chamber.
  • the characteristic gas-solid contact times and the characteristic gas-particle heat transfer times can be very small compared to the kinetics of the decomposition CaCO 3 particles, it is theoretically possible overheat the carbonated particles in the cyclone above the equilibrium decomposition temperature of CaCO 3 under the CO 2 partial pressure in the flue gases that abandons the combustion chamber. In these conditions, the carbonated particles could be theoretically heated up and separated from the flue gas at temperatures approaching the decomposition temperature of CaCO 3 in pure CO 2 at atmospheric pressure (900° C.) because these separated particles would be surrounded by a rich CO 2 atmosphere created by the decomposition of CaCO 3 in the small void volumes that accompany the solid stream of particles.
  • Another potential improvement in order to minimize the fuel consumption dedicated to the preheating of carbonated solids in the device of the system of this invention, is to increase the number of heat exchange stages (as those described with the third and fourth cyclones) so that the exit temperature of the cooled flue gas is closer to the inlet temperature of the carbonated solids.
  • the carbonated solids stream could be put in direct contact with the CO 2 generated in the calciner in an additional heat exchanging step similar to the one taking place in the fourth cyclone, bringing the temperature of the carbonated solids closer to the calciner conditions.
  • the system of this invention can supply to the calciner an overheated stream of carbonated solids at temperatures between 750-900° C., preferably between 750-800° C.
  • this reduction of the heat requirements in the calciner translates into a reduction of the high temperature flue gas required to heat up the overheated calcined solids transporting heat to the calciner, thereby reducing the requirements of CaO to capture CO 2 in the carbonator and hence the flow of carbonated solids generated in the carbonator and entering the calciner.
  • the system of this invention can yield a substantial reduction of the energy requirements in the calciner irrespective of the particular calciner design.
  • the calciner is based on the oxycombustion of coal in the calciner, there will be a substantial reduction in O 2 and fuel consumption in the calciner.
  • the design of the calciner can be simplified as a result of the reduced heat requirements. This can lead to several embodiments of the invention and to other variants for other calcium looping schemes that should be evident for a skilled person in the art when using the teachings of the present invention.
  • FIG. 1 shows a preferred embodiment of the Calcium looping system of this invention.
  • FIG. 2 shows another preferred embodiment of the Calcium looping system of this invention, applied to an existing power plant burning natural gas in a combined cycle.
  • This invention refers to a system to capture CO 2 from a combustion flue gas using a CaO/CaCO 3 chemical loop.
  • a preferred embodiment of the system disclosed in this invention is represented in FIG. 1 and is intended for the combustion of a fuel to generate useful heat, comprising the following elements:
  • the reduction in heat requirements in the calciner ( 52 ) by the increase of the inlet temperature of carbonated solids translates into a substantial reduction in the energy requirements in the calciner ( 52 ).
  • a second solution (not shown in the FIG. 1 for simplicity but shown in a part of FIG. 2 ) would be to dedicate an additional combustion chamber for the purpose of generating a higher temperature flue gas ( 6 ) to heat up the recirculating stream of CaO in the third cyclone ( 55 ).
  • the twelfth pipe ( 12 ) is supplying flue gas that enters into contact with carbonated solids ( 10 ) before the fourth cyclone ( 56 ).
  • the combustion of a certain flow of fuel in O 2 would be required in these conditions in the calciner ( 52 ).
  • FIG. 2 a second preferred embodiment of the system disclosed in FIG. 1 is presented in FIG. 2 . This is intended for application to an existing combustion power plant comprising:
  • Similar devices can be designed following the teachings of this invention for precombustion CO 2 capture systems using CaO as a regenerable sorbent, calcium looping system with reactivation steps, calcium looping systems with energy storage by accumulating high temperature solids and low temperature solids, and calcium looping systems where the calcination heat is coming from an exothermic reaction of a second solid reacting in the system other than combustion of a fuel in O 2 . Therefore, the description and examples provided in this invention are illustrative and of non-limiting character.
  • FIG. 1 A conceptual design of a device a FIG. 1 is carried out below to illustrate its practical application.
  • the operating conditions in the example have been chosen to show that it is possible to operate the calciner ( 52 ) without the need of a supply of fuel and O 2 to such calciner ( 52 ).
  • a heat supply in the calciner ( 52 ) of at least 53.6 MW would be needed in order to heat up the stream of carbonated solid from 650 to 915° C. (24.2 MW) and to calcine the carbonate (29.4 MW) formed in the carbonator ( 51 ).
  • a heat supply in the calciner ( 52 ) of at least 53.6 MW would be needed in order to heat up the stream of carbonated solid from 650 to 915° C. (24.2 MW) and to calcine the carbonate (29.4 MW) formed in the carbonator ( 51 ).
  • this example has been chosen to show that it is possible to operate the calciner ( 52 ) without the need of a supply of fuel and O 2 to such calciner ( 52 ).
  • a heat balance indicates that the supply of the 44.8 MW required in the calciner ( 52 ) with the overheated solid stream of recirculating solids to the calciner ( 52 ) requires 527 kg/s of recirculating solids through eighth pipe ( 8 ). This is 5.8 times the solid circulation between reactors.
  • This recirculating flow of solids is high, but within the limits of what is feasible in state of the art of circulating fluidized bed technology.
  • the operation of the calciner ( 52 ) with these high total solid circulation rates may require a design of the bottom part of the calciner with a large cross-section, in order to allow for sufficient bed inventory of solids and sufficient residence time (10 to 20 seconds) of the solids in the calciner.
  • the temperatures and solid circulation rates required to enter the third cyclone ( 55 ) of this example in order to close the heat balance in the calciner are relatively high, in particular the target temperature for overheated calcined solids (1000° C.) and the solid recirculation flow of these solids (527 kg/s of recirculating solids plus the 83.6 kg/s circulating between calciner and carbonator respect to a gas mass flow abandoning the calciner of 8.6 kg/s). There will be practical situations where these high temperatures and solid circulation conditions cannot be reached.
  • a particular example of application of the system of this invention arises when considering its application to the case of an existing power plant comprising a first combustion chamber ( 50 ) generating a flue gas at low temperature through first pipe ( 1 ) entering the carbonator ( 51 ). Therefore, in these applications, there is no heat available for the calcium looping system from the flue gases generated in the main combustion chamber ( 1 ). Additional combustion chambers are needed to supply the hot flue gases of sixth ( 6 ) and twelfth ( 12 ) pipes of FIG. 1 .
  • the conceptual design of a preferred embodiment of the system of this invention to solve this particular case is represented in FIG. 2 .
  • a natural gas combined cycle, NGCC is used to represent such power plant.
  • Coal or biomass of other carbonaceous fuel combustion systems would follow a similar design procedure.
  • the CO 2 capture efficiency in the carbonator is 85% for the lower CO 2 content of flue gases derived from natural gas combustion
  • the temperature of calcination is 900° C., as the oxy-combustion of natural gas in the calciner ( 52 ) generates a large fraction of steam that facilitates the fast calcination of CaCO 3 at lower temperatures
  • the temperature of the overheated recirculation of CaO is limited to 950° to avoid possible enhanced deactivation of the CaO sorbent particles
  • the solid recirculation of CaO in the calciner ( 52 ) is limited to a solid more conservative value of 250 kg/s, more similar to the existing in circulating fluidized bed combustors and associated cyclones with dimensions comparable to the carbonator reactor.
  • a second combustor of natural gas ( 57 ) is installed to supply a high temperature flue gas ( 23 ) to enter in contact with the recirculating stream of CaO solids through the seventh pipe ( 7 ).
  • the flue gas that abandons the third cyclone ( 55 ) at 950° ( 55 ) is directed to the fourth cyclone ( 56 ) to heat up the carbonated solid stream at 650° C. ( 10 ) up to a temperature of 691.4° C.
  • a third combustor ( 58 ) is chosen to supply heat to a fifth cyclone ( 59 ).
  • this combustor operates at temperature and air excess as in the second combustor, burning in this case a flow of natural gas of 0.08 kg/s and air of 1.39 kg/s.
  • this small third combustor could be designed to target much higher overheating temperatures of the carbonated solids by burning a different fuel with a higher carbon content, by using comburents with higher O 2 content (enriched air) and/or by operating in a gas-solid contact mode to allow overheating of carbonated particles to temperatures over the equilibrium decomposition temperature of CaCO 3 in the flue gas CO 2 partial pressure and below the decomposition temperature of CaCO 3 in pure CO 2 at the pressure of the fifth cyclone (900° C. at atmospheric pressure).
  • the increase in the temperature of the carbonated solids from 650 to 750° C. in the fourth and fifth cyclones reduces in 5.4 MW the heat requirements in the calciner ( 52 ).
  • the increase in the temperature of the recirculated calciner solids from 900 to 950° C. in the third cyclone reduces in 12.5 MW the heat requirements in the calciner ( 52 ).
  • the closure of the heat balance of the calciner is achieved in this example using state of the art oxycombustion of natural gas ( 19 ) in the calciner ( 52 ) with a O 2 —CO 2 comburent mixture ( 20 ).

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EP13382206.4A EP2808073B1 (en) 2013-05-31 2013-05-31 System for CO2 capture from a combustion flue gas using a CaO/CaCO3 chemical loop
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